Makita 903D User manual

n
Overall length
No load speed
IRPM)
Collet size
3 mm or 1 /E'' 19,000 295 mm I1 1 518'')
MODEL 903D
MODEL 903DW
With Fast Charger
Net weight
0 7 kg 11.5 Ibs)
INSTRUCTION MANUAL
Battery Cartridge 9000
"'"I
Model DC9100 Fast Charger
Voltage I Charging time I Input I output
96V I 1 Hr I AC only 50Hr ~ 60 Hz I DC 9 6V
~~ ~~ ~
Manufacturer reserves the right to change specifications without notice.
Note: Specifications may differ from country to country.

IMPORTANT
SAFETY INSTRUCTIONS
(For All Tools)
WARNING:
WHEN USING ELECTRIC TOOLS, BASIC SAFE-
REDUCE THE RISK OF FIRE, ELECTRIC SHOCK, AND PER-
TY PRECAUTIONS SHOULD ALWAYS BE FOLLOWED TO
SONAL INJURY, INCLUDING THE FOLLOWING:
READ ALL INSTRUCTIONS.
1. KEEP WORK AREA CLEAN. Cluttered areas and benches invite injuries.
2. CONSIDER WORK AREA ENVIRONMENT. Don't use power tools in damp
or wet locations. Keep work area well
lit. Don't expose power tools to rain.
Don't use tool in presence of flammable liquids or gases.
3. KEEP CHILDREN AWAY. All visitors should be kept away from work area.
Don't let visitors contact tool or extension cord.
4. STORE IDLETOOLS. When not inuse, tools should be stored indry, and high
or locked-up place
- out of reach of children.
5. DON'T FORCETOOL. It will dothejob better andsafer at the rate for which
it was intended.
6. USE RIGHT TOOL. Don't force small tool or attachment to do the job of a
heavy-duty tool. Don't use tool for purpose not intended.
7. DRESS PROPERLY. Don't wear looseclothing orjewelry. They can becaught
in moving parts. Rubber gloves and non-skid footwear are recommended
when working outdoors. Wear protective hair covering tocontain long hair.
8. USE SAFETY GLASSES. Also use face or dust mask if cutting operation is
dusty.
9. DON'T ABUSE CORD. Never carry tool by cord or yank it todisconnect from
receptacle. Keep cord from heat, oil, and sharp edges.
IO. SECURE WORK. Use clamps or a vise to hold work. It's safer than using
your hand and it frees both hands to operate tool.
11. DON'T OVERREACH. Keep proper footing and balance at all times.
12. MAINTAIN TOOLS WITH CARE. Keep tools sharp and clean for better and
safer performance. Follow instructions for lubricating and changing acces-
sories. Inspecttoolcords periodicallyand if damaged, have repairedbyautho-
rized service facility. Inspect extension cords periodically and replace if
damaged. Keep handles dry, clean, and free from oil and grease.
13. DISCONNECTTOOLS. When not in use, before servicing, and when chang-
ing accessories, such as blades, bits, cutters.

14. REMOVE ADJUSTING KEYS AND WRENCHES. Form habit of checking to
see that keysand adjusting wrenches are removed from tool before turning
it on.
15. AVOID UNINTENTIONALSTARTING. Don't carry plugged-intool withfinger
on switch. Be sure switch is OFF when plugging in.
16. OUTDOOR USE EXTENSIONCORDS. Whentool is used outdoors, use only
extension cords intended for use outdoors and
so marked.
17. STAY ALERT. Watchwhat you are doing, usecommon sense. Don't operate
tool when you are tired.
18. CHECK DAMAGED PARTS. Before further use of the tool, a guard or other
part that is damaged should be carefully checked to determine that
it will
operate properly and perform its intended function. Check for alignment of
movingparts, bindingof moving parts, breakageof parts, mounting, andany
other conditions that may affect its operation. A guard or other part that
is damaged should be properly repaired or replaced by an authorized serv-
ice center unless otherwise indicatedelsewhere
in this instruction manual.
Have defective switches replaced by authorized service center. Don't use
tool
if switch does not turn it on and off.
19. GUARD AGAINST ELECTRIC SHOCK. Prevent body contact with grounded
surfaces. For example; pipes, radiators, ranges, refrigerator enclosures.
20. REPLACEMENT PARTS. When servicing, useonly identicalreplacementparts.
VOLTAGE WARNING: Before connectingthe tool to a power source (receptacle,
outlet, etc.) be sure the voltage supplied is the same as that specified on the
nameplate of the tool. A power source with voltage greater than that specified
for the tool can result
in SERIOUS INJURYto the user - as well as damage to
the tool.
If in doubt, DO NOT PLUG IN THE TOOL. Using a power source with
voltage less than the nameplate rating is harmful to the motor.
3

1. SAVE THESE INSTRUCTIONS - This manual
contains important safety and operating instructions for battery charger.
2. Before using battery charger, read all instructions and cautionary markings
on
(1) battery charger, (2) battery, and (3) product using battery.
3. CAUTION - To reduce risk of injury, charge only MAKITA Battery 9000.
Other types of batteries may burst causing personal injury and damage.
4. Do not expose charger to rain or snow.
5. Use of an attachment not recommended or sold by the battery charger
manufacturer may result ina riskof fire, electric shock, or injurytopersons.
6. To reduce risk of damage toelectric plug andcord, pull by plug rather than
cord when disconnecting charger.
7. Make sure cord islocated so that it will not be stepped on, tripped over, or
otherwise subjected to damage or stress.
8. An extension cord should not be used unless absolutely necessary. Use of
improper extension cord could result
in a risk of fire and electric shock. If
extension cord must be used, make sure:
a. That pinsonplugof extensioncord are the same number, size, andshape
b. That extension cord
is properly wired and in good electricalcondition; and
c. That wire size isat least as large as the one specified inthe table below.
TABLE
1
RECOMMENDED MINIMUM AWG SIZE FOR
EXTENSION CORDS
FOR BATTERY CHARGERS
as those of plug on charger;
~~ ~
Length of Cord (Feet)
AWG Size of Cord
25 50
100 150
18 18 18 16
9. Do not operate charger with damaged cord or plug - replace them im-
mediately.
IO. Do notoperate charger if it has receivedasharp blow, beendropped, or other-
wise damaged in any way; take
it to a qualified serviceman.
11. Do not disassemble charger or battery cartridge; take it to a qualified
serviceman when service or repair is required. Incorrect reassembly may
result
in a risk of electric shock or fire.
12. To reducerisk of electric shock, unplug charger from outlet beforeattempt-
ingany maintenanceor cleaning.Turning
off controls will not reducethis risk.
4

ADDITIONAL SAFETY RULES
FOR CHARGER
& BATTERY CARTRIDGE
1. Do not charge Battery Cartridge when temperature is BELOW 10°C (SOOF)
or ABOVE 4OoC
(104OF).
2. Donotattempttouse astep-up transformer, an enginegenerator or DC power
3. Do not allow anything to cover or clog the charger vents.
4. Do not short the battery cartridge:
receptacle.
(1)Do not touch the terminals with any conductive material.
(2) Avoid storing batterycartridge inacontainer with other metalobjects such
(3) Do not expose battery cartridge to water or rain.
A battery short can cause a large current flow, overheating, possible burns
and even a breakdown.
5. Do not store the tool and Battery Cartridge in locations where the tempera-
ture may reach or exceed 5OoC (122OF).
6. Do not incinerate the Battery Cartridge even if it is severely damaged or is
completely worn out. The battery cartridge can explode
in a fire.
as nails, coins, etc.
ADDITIONAL SAFETY RULES
1. Be aware that this tool is always inan operating condition, because it does
2. Use only wheel points having a maximum operating speed at least as high
3. Check the wheel point carefully for cracks or damage before operation.
4. Hold the tool firmly.
5. Keep hands away from rotating parts.
6. Before using the tool on an actual workpiece, let it run for more than one
minute. (When mounting a new wheel point, let
it run for more than three
minutes.) Watch for vibration or wobbling that could indicate poor installa-
tion or a poorly balanced wheel point.
7. Watch out for flying sparks. Hold the tool so that sparks fly away from you
and other persons or flammable materials.
8. Do not leave the tool running. Operate the tool only when hand-held.
9. Always besure you have afirmfooting. Be sure noone isbelow when using
not have to be plugged into an electrical outlet.
as
"No Load RPM" marked on the tool's nameplate.
Replace cracked or damaged wheel point immediately.
the tool in high locations.
IO. Do not use water or grinding lubricant.
11. Do not use this tool as cutter.
12. Donottouch the workpiece immediately after operation; it may beextremely
hot and could burn your skin.
5
SAVE THESE INSTRUCTIONS.

Installingor removingbattery cartridge
0 Always switch off the tool before insertion or removal of the battery cartridge.
0 To remove the battery cartridge, pull out
the
set plate on the tool and grasp both
sides of the cartridge while withdrawing
it
from the barrel.
0 To insert the battery cartridge, align the
tongue on the battery cartridge with the
groove in the housing and slip
it into
place. Snap the
set plate back intoplace.
Be sure to close the
set plate fully before
using the tool.
I
Battery cartridge
I
0 Do not use force when inserting the battery cartridge.
If the cartridge does notslide ineasily,
it is not beinginsertedcorrectly.
Charging
Plug the fast charger into your power
source. Insert the battery cartridge
so that
the plus and minus terminals on the bat-
tery cartridge are on the same sides
as their
respective markings on the fast charger.
Insert the cartridge fully into the port
so
that it rests on the charger portfloor.
Press the start button (red). The charging
light will come on and chargingwill begin.
If the charginglight does notcome on, press the reset button (yellow)first, then the start
button (red). If the charginglightgoes outwithin
10 seconds even after pressing the reset
buttonand start button
a couple of times, the battery cartridge is dead. (CAUTION : Wait
for more than 5 seconds after the charginglight goes out to press the reset buttonagain.)
Replace
it with a new one. When the charging light goes out after about one hour, you
may remove the fully charged battery cartridge.
After charging, unplugthe charger from the power source.
CAUTION
:
0 Your new battery cartridge is notcharged. You will need to charge it before use.
0 Do not keep the button pressed in with tape, etc., or the circuitwill notfunction pro-
perly. Also,
a malfunction of the charger may result possiblycausingoverheating, etc.
0 If you try to charge a cartridge from a just-operated tool, sometimes the charginglight
will not come on. If this occurs,
let the cartridge cool off for a while. Then re-insert it
and try to charge it once more.
0 When you charge a new battery cartridge or a battery cartridge which has not been used
for
a long period, it may not accept a full charge. This is a normal condition and does
not indicate
a problem. You can recharge the battery cartridge fully after discharging
it completely a couple of times.
0 If you wish to charge two battery cartridges, allow 15 minutes betweenchargingson the
fast charger.
6

Installingor removing wheel point
CAUTION :
Always be sure that the tool is switched off and the battery cartridge is removedbefore
installing or removing the wheel point.
Remove the guide from the tool when
it is
installed on the tool. Loosenthe wing bolt
and pull the guide off the front end of the
tool.
Press the shaft lock to lock the spindle in
place. Loosen the collet nut and insert the
wheel point intothe collet nut.
Use the gauge (the gauge has
a hex hole
which can be used
as a wrench) to tighten
the collet nutsecurely.
Shaft lock
The wheel point should not be mounted
more than
10 mm (3/8") from the collet
nut. Exceeding this distance could cause
vibrationor
a broken shaft.
To removethe wheel point, follow the installation procedures in reverse.
7

Switch action
CAUTION :
Before inserting the battery cartridge into the tool, always check to see that the switch
lever actuates properly and returns tothe
“OFF” positionwhen released.
Operation
Switch on the tool and wait until the wheel
point attains full speed. Then apply the
wheel point to the blade gently.
To sharpen
the blade, move the tool while maintain-
ing the angle of the wheel point in relation
tothe blade.
CAUTION
:
Apply light pressure on the tool. Excessive pressure on the tool will only cause a poor
finish and actuation of the overload protector.
Overload protector
The overload protector automatically cuts out to break the circuitwhenever heavy work
is prolonged. When this occurs, release the switch lever and withdraw the tool from the
blade.
Wait untilthe motor cools down and then resumeoperation.
8

Chain blade sharpening attachment
1. Read the instruction manual of yo:' chain saw to determine the size of wheel point,
the top plate filing angle
(30" or 35 ) andthe depth gauge clearance [0.025" (0.64 mm),
0.030"(0.76 mm), 0.035" (0.89 mm) or 0.040'(1.02 mm)] before use.
17
Too date filinq anqle I
Depth gauge
clearance
2. Three sizes of wheel points are available: 5/32" (4.0 mm), 3/16" (4.8 mm) and 7/32"
(5.5mm). Select a proper wheel point for chain cutters to be sharpened.
3. Attach the guide to the tool as shown
in the figure after installing the wheel
point. Semi-tighten the wing bolt to the
extent that the guide can be turned.
4. Place the guideonthe gauge as shown in
the figure and turn the guide until the
wheel point fits into the appropriate
wheel
size slot in the gauge. (Thewheel
point will raise up out of the bottom
of the slot by turning the guidecounter-
clockwise). After adjusting the wheel
point
to fit into the slot, tighten the
wing boltsecurely.
Wheel point
I
Guide
I
9

This will allow approx. 1/5 of the wheel
point diameter to protrude above the
chain cutters
as chain manufacturersre-
commend.
NOTE
:
Always check the protrusion of the wheel point using the gauge after tightening the
wing bolt securely because the guide may move when you tighten the wing boltsecure-
ly.
1/5 of wheel pointdiameter
%
Place the wheel point on the chain so
that the wheel point fits into the chain
cutter and the guide line
(30" or 35")
on the guide is parallel to the chain.
Switch on the tool and wait until the
wheel point attains full speed. Then
move the tool back and forth several
times while maintainingthe wheel point
level or at 10" in relation to the chain.
(Referto the instruction manualof your
chain saw whether you should maintain
the wheel point
level or maintain it at
IO".)
1 Chain
Level
___)
1 oo
CAUTION :
Place the wheel point on the chain before switching on and remove the wheel point
from the chain after the wheel point has come to
a completestop. Otherwise the rotat-
ingwheel point may damage the chain cutters.
10

5. The depth gauges (or "rakers") of the chain cutter should be checked every third or
fourth chainsharpening and lowered
if found to be too high.
To do this, place the guide on the gauge
as shown inthe figure and turn theguide
until the wheel point fits into the ap-
propriate depth gauge slot inthe gauge.
Hang the gauge on the chain and push
the gauge against the guide bar.
Place
the guide on the gauge and switch on
the tool. Move the tool left and rightto
grind away excess height
of the depth
gauge.
Guide
I
Chain
I Guide ,
11

MAINTENANCE
CAUTION :
Always be sure that the tool is switched off and the battery cartridge is removedbefore
attempting to perform inspectionor maintenance.
To maintain product SAFETY and RELIABILITY, repairs, maintenance
or adjustment
should be performed by Makita Authorized or Factory Service Centers, always using
Makita replacementparts.
12

ACCESSORIES
CAUTION :
These accessories or attachments are recommended for use with your Makita tool specified in this
manual. The use
of any other accessoriesor attachmentsmight present a risk of injury to persons.The
accessories or attachmentsshould be used only inthe proper and intended manner.
Wheel diameter
(mm)
Part No.
e Battery cartridge 9000
Part No.632007-4
Overall length
Abrasive material
("1
e 12 V Fast charger
Model DC9012
741603-8
741604-6
741607-0
741608-8
741622-4
74 16 18-5
741623-2
741619-3
741624-0
741620-8
~
e Gauge
Part No. 762015-2
A
WA
5 (3/16")
6 (1/4")
5 (3/16")
6 (1/4")
- 43 (1-11/16")
-
43 (1-11/16")
4 (5/32")
4.8 (3/16") 46 (1-13/16") PA
-
5.5 (7/32")
e Wheel point
e Fast charger
Model DC9100
e Battery holster
Holster holds extra battery.
Part No. 823033-3C
Guide
Part No. STEX 122399
e 1/8" shank size
A - To grind mild steel, carbon steel etc.
WA - To grind hardenedandspecial steels.
PA - To grindalloy steel and carbonsteel for tool.
13

May-09-89 EN
I CORDLESS BLADE SHARPENER
@- Model 903D
Note:The switch and other part configurations
may differ from country to country.
14

MODEL 903D May-09-89 EN
11
21
31
41
51
61
71
‘:“OM DESCRIPTION
Name Plate
Housing Set lWath Item 11 1
Battery Holder
Switch
Compression Spring 6
Switch Lever
Collet Nut 3
‘EM DESCRIPTION
8 1 Collel Body 3 mm
9 1 Ball Bearing 607LLB
10 1 DC Motor96V
11 1 Hou~ing Set IWith Item 21
12 6 Pan Head Screw M4x22 IWith Washed
13
1 Set Plate
14 1 Battery 9000
Note. The switch and other part specificat,ons may differ from country to country.

MAKmA LIMITEDONE YEAR WARRANTY
Warranty Policy
Every Makita tool is thoroughly inspected and tested before leavingthe factory. It is warranted to
be free of defects from workmanship and materials for the period of ONE YEAR from the date
of
original purchase. Should any trouble develop during this one-year period, return the COMPLETE
tool, freight prepaid, toone of Makita’s Factory or Authorized ServiceCenters. If inspection shows
the trouble is caused by defective workmanship or material, Makita will repair (or at our option,
replace) withoutcharge.
This Warranty does not apply where:
repairs have been made or attempted by others:
repairs are required because of normal wear and tear:
Thetool has been abused, misused or improperly maintained;
alterationshave been made to the tool.
IN NO EVENT SHALL MAKITA BE LIABLE FOR ANY INDIRECT, INCIDENTALOR CON-
SEQUENTIAL DAMAGESFROM THE SALE OR USE OF THE PRODUCT.THIS DISCLAIMER
APPLIES BOTH DURING AND AFTER THE TERM OFTHIS WARRANTY.
MAKITA DISCLAIMS LIABILITY FOR ANY IMPLIED WARRANTIES, INCLUDING IMPLIED
WARRANTIES OF “MERCHANTABILITY” AND “FITNESS FOR A SPECIFIC PURPOSE,”
AFTER THE ONE-YEAR TERM OFTHIS WARRANTY.
Ths Warranty pes
you specific legal rights, and you may also have other nghts which vary from
state
to state. Some states do not allow the exclusion or limitation of incidental or consequential
damages,
so the above limitation or exclusion may not apply to you. Some states
do not allow
limitation
on how long an implied warranty lasts, so the above limitation may not apply to you.
~~ - -,u.
11-8.3-chome, Sumiyorhi-cho.Anjo, Aichi 446, Japan
883703 - 061
PRINTED INJAPAN
1989 - 10 - N